Redundant reusable high volume cushion

ABSTRACT

A redundant reusable high volume cushion with refillable tandem tubes comprised of redundant cushion areas having two or four discrete areas comprised of redundant geometrically shaped chambers creating a high volume cushion. The redundant cushion areas facilitates absorption of impact upon the cushion by permitting redistribution of an inflation gas, e.g., air, from an area of impact to a non-impacted area within the same cushion. Entry/exit tandem tubes control the flow of inflation gas into and/or out of the cushion.

FIELD OF THE INVENTION

The invention is directed to impact-resistant redundant reusable highvolume cushions for protecting articles during shipping from shock anddamage and, more particularly, to a reusable, inflatable multi-arearedundant reusable high volume material that provides a higher fillvolume profile, provided with an air entry portal adapted for permittingindependent inflation/deflation of redundant areas.

BACKGROUND OF THE INVENTION

When articles are packaged in a container for shipping, void spaces aretypically created between the article and the inner surface of thecontainer. Packaged articles come in a variety of shapes, thus producinga plurality of irregularly shaped voids. A redundant reusable highvolume material is thus commonly inserted within these voids to cushionand protect the packaged article during shipping.

It is known, therefore, to at least partially surround shipped articleswith redundant reusable high volume materials having a variety of shapesand sizes such as Styrofoam® “chips,” injected Styrofoam® moldings,“bubble” mats and other energy absorptive materials. “Bubble” mats, areintended to wrap close to the shipped item providing an enclosure thatprotects the item, but the spaces between the “bubble” mat protecteditem and the interior surfaces of the container are largely filled witha volume of a loose fill type material Styrofoam® “chips,” and otherparticulate redundant reusable high volume materials provide a loosefill and the packaged article may settle during transport, reducing thecushioning effect. Moreover all of the above—described redundantreusable high volume materials are themselves voluminous to both shipand store. In addition, they could create waste disposal problems withattendant problems of environmental degradation.

In an effort to overcome the problems noted above, various forms ofinflated cushions have been utilized. Such cushions are well known andhave been commonly used for some time in the shipment of goods. Severaluseful examples of inflatable cushions are illustrated in, for example,U.S. Pat. Nos. 5,427,830; 5,447,235 and 5,487,470 to David A. Pharo. Theinflatable packaging systems described therein, and throughout the priorart have been faced with a number of design challenges, however.

For example, some of the inflatable cushions include only a singleinflatable area, such that a failure at any location in the packagingmaterial will lead to a total deflation of the system, thus resulting ina total loss of function. Other examples include cushions with aplurality of interconnected inflatable areas, i.e., providing, a“quilted” appearance to the cushion. This arrangement still remainsprone, however, to the deflation problem described above. Still otherembodiments comprise a plurality of discrete, i.e., separate, chambers,which do not, as is desirable, permit redistribution of air within thecushion, i.e., from one chamber to another, upon impact to the outersurface of one or more such chambers. Additionally, many such prior artinflatable redundant reusable high volume systems are further subject toother problems, as described below, caused due to the use of valvesystems that may channel air under impact pressure directly toward thevalve cap forcing open the valve, or self-sealing valves that are mosteffective when cushions maintain a consistent pressure once inflated,this consistent pressure provides a back pressure helping to make thevalve self-sealing. Thus, the dimensions of these inflatable cushionsmay find it difficult to adjust to different sized voids within aredundant reusable high volume container. Still further, due to the verynature of the self-sealing valves such inflatable devices are typicallynot readily reusable since it is difficult, if not impossible, to emptythe air out of an inflated cushion or cushion without reducing theuseful life of each cushion, i.e. puncturing the cushion or disruptingthe self-sealing properties.

It is thus readily apparent that there exists a long-felt need, which issatisfied by the present invention as described herein, for a reliable,efficient, adjustably inflatable protective packaging cushion, withredundant areas and a higher volume profile, for protecting fragileand/or valuable items during shipping. The present invention meets theserequirements with a simple design that is readily and convenientlymanufactured from inexpensive starting materials. It may be used, andreused, for an unlimited variety of shapes and sizes of product beingpackaged. The protective inflatable cushion that is self-adapting to thesize and shape of the item being packaged, which will not settle duringshipment, and that will secure itself around the object to be shippedwhile substantially filling all of the void spaces between the objectand the outer container. The object of the invention is thus relativelysimple to ship and store and it is cost competitive with presentlyexisting systems.

SUMMARY OF THE INVENTION

It is therefore an object of the invention to provide a redundant,reusable high volume cushion formed with at least two separatelyinflatable and deflatable redundant areas, adapted to facilitateabsorption of impact to the cushion and to redistribute air fromredundant area compressed by the impact to alternate redundant areas.

It is another object of the invention to provide chambers with a conicalshape or configuration such that, maximum inflated cushion height can beachieved in a redundant area format, by balancing these conical chambersit is possible to provide security in the event one air chamber ispunctured in that adjacent unaffected (i.e., unpunctured) redundant areawill assist in maintaining the inflated height of the cushion upon suchan event due to crossing-over of said redundant areas provided bycushion redundant area layout.

It is another object of the invention to provide an inflatable,redundant reusable high volume cushion wherein the flow of air into thecushion is controlled by refillable tandem tubes creating at least onearea entry/exit portal which, due to its design and construction, allowsthis portal to withstand a significant air pressure caused due toimpact, i.e., causing compression, upon one of the inflated redundantareas of the cushion, without forcing the portal open.

These and other objects of the invention are achieved through the use ofan inflatable, redundant reusable high volume cushion with refillabletandem tubes as described and illustrated herein.

In a first embodiment the invention is directed to a two area redundantreusable high volume cushion which, areas can be aligned side by sidecomprising a two area entry/exit portal tube. Areas can also be alignedtop and bottom, and right and left sides wherein each said area directsimpacted air pressure through the central core of the cushion layout,also utilizing a two area entry/exit portal tube. In a furtherembodiment, the redundant reusable high volume cushion of the inventioncomprises a four area redundant reusable high volume cushion utilizing afour area refillable tandem tubes entry/exit portal tube wherein eachsaid area controls the flow of air into and out of a separate said area.The four area cushion offers additional protection from accidentaldeflation throughout the handling process.

The system of invention was designed with redundant areas, each formedwith redundant air chambers, in a single redundant reusable high volumecushion to allow each cushion the ability to absorb impact bydistributing air to chambers not compressed by impact. That is, thecushion comprises at least two inflation areas, and each said area maybe further broken down into a plurality of inflatable chambers. Theredundant reusable high volume cushion of the invention can bemanufactured in a variety of shapes and sizes, that utilize a taperedredundant cushion area to deliver the high volume developed through theconical taper, or conical like taper and from a variety of materials aswell. FIG. 1, FIG. 15 and FIG. 12, FIG. 25, illustrating, respectively,a two area and a four area cushion, FIG. 1 and FIG. 15, display anexemplary geometric design for the cushion chambers wherein saidchambers are conical shaped and use the maximum film surface, providinga high volume profile with added redundant area format security. Theinvention is not limited, however, to the particular arrangementportrayed in the subject drawing figures. That is, whereas a conicalconfiguration is preferred, the chambers of the cushion of the inventionare not limited to a conical shape and may, instead, be configured in avariety of alternate shapes that provide a conical like taper. In theillustrated embodiment, the cushion fill height can be increased bymaking the conical chambers larger. Cushions can also be made longer andshorter by adding or subtracting cones from a design layout. Thisflexibility of design thus provides a custom system useful for a varietyof applications, while still offering the same degree of area security.

The ability to be inflated or deflated (see, e.g., FIG. 1 and FIG. 11,FIG. 15 and FIG. 24) as the task requires, provides a reusable redundantreusable high volume cushion for all users in the shipping cycle. Theredundant reusable high volume cushion of the invention can be storeddeflated when not in use, thus reducing storage space requirements.

The system of the invention, comprising a redundant reusable high volumecushion with refillable tandem tubes at least one, area entry/exitportal, is inflated and deflated through the use of the area entry/exitportal tube and requires no special equipment to operate. The cushionscan be filled by mouth or with compressed air, allowing the end user tostore, reuse and recycle this redundant reusable high volume fill. Thesystem of the invention, comprising a redundant reusable high volumecushion with refillable tandem tubes can be stored as raw film material,assembled and inflated by the manufacturer, then deflated by the enduser by cutting the refillable tandem tubes air portals and reused bythe end user, by putting air back into the refillable tandem tubes airportal, providing once again the redundant reusable high volume cushion.Security against unintended deflation is thus provided through areadesign and the entry/exit portal tube tuck-away as further describedherein.

The redundant reusable high volume cushion with refillable tandem tubesmay be printed with a company logo or other graphics inside and out,thus allowing redundant reusable high volume cushion with refillabletandem tubes to be a marketing image piece.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing objects and other advantages of the present invention willbe more fully understood from the following detailed description andreference to the appended drawings, wherein:

FIG. 1 is a top plan view of the side by side two area redundantreusable high volume cushion with refillable tandem tubes

FIG. 2 is a perspective view of a side by side two area redundantreusable high volume cushion with refillable tandem tubes

FIG. 3 is a component view of the side by side two-area redundantreusable high volume cushion with refillable tandem tubes, illustratingrelationship between the A and B film entry/exit portal tube and areaconical air chamber layout.

FIG. 4 is a perspective view of an inflated side by side two arearedundant reusable high volume cushion with refillable tandem tubes,illustrating the inflated entry/exit portal tube and the interior arealayout.

FIG. 5 is a perspective view of an inflated side by side two arearedundant reusable high volume cushion with refillable tandem tubes,

FIG. 6 is a perspective close-up view of an inflated side by side twoarea redundant reusable high volume cushion, illustrating the inflatedentry/exit portal tube

FIG. 7 is a close-up front view of an inflated side by side two arearedundant reusable high volume cushion with refillable tandem tubes,illustrating the inflated entry/exit portal tube

FIG. 8 is a close-up front view of the side by side two-area redundantreusable high volume cushion with refillable tandem tubes, illustratingthe inflated entry/exit portal tube with the first closing fold.

FIG. 9 is a close-up front view of the side by side two-area redundantreusable high volume cushion with refillable tandem tubes, illustratingthe inflated entry/exit portal tube with the second closing fold.

FIG. 10 is a close-up front view of side by side two-area redundantreusable high volume cushion with refillable tandem tubes, illustratingthe inflated entry/exit portal tube in the tuck-away position.

FIG. 11 is a perspective view of an inflated side by side two arearedundant reusable high volume cushion with refillable tandem tubes,illustrating the closed tuck-away position of the entry/exit portaltube.

FIG. 12 is a component view of the side by side four-area redundantreusable high volume cushion with refillable tandem tubes, illustratingrelationship between the A and B film entry/exit portal tube and areaconical air chamber layout and the center C film that creates the fourareas.

FIG. 13 is a top plan view of the side by side two-area or four-arearedundant reusable high volume cushion with refillable tandem tubes,illustrating layout orientation of two separate cushions in a productionlayout

FIG. 14 is a top plan view of the side by side two-area or four-arearedundant reusable high volume cushion with refillable tandem tubes,illustrating layout orientation of two separate cushions and additionalsimilar arranged cushions in a production layout to accommodate rolledor sheet film raw material.

FIG. 15 is a top plan view of the top to bottom and side to side twoarea redundant reusable high volume cushion with refillable tandem tubes

FIG. 16 is a perspective view of a top to bottom and side to side twoarea redundant reusable high volume cushion with refillable tandemtubes.

FIG. 17 is a component view of the top to bottom and side to sidetwo-area redundant reusable high volume cushion with refillable tandemtubes, illustrating relationship between the A and B film entry/exitportal tube, central core film and area conical air chamber layout.

FIG. 18 is a top perspective view of the top to bottom and side to sidetwo area redundant reusable high volume cushion central core film,illustrating the heat-weld seams in the A film that create air passageto the area two air chambers.

FIG. 19 is a through perspective view of the top to bottom and side toside two area redundant reusable high volume cushion with refillabletandem tubes central core film, illustrating the heat-weld seams in theB film that create air passage to the area one air chambers and theirrelationship to area two air passageway.

FIG. 20 is a through perspective view of the top to bottom and side toside two area redundant reusable high volume cushion with A and B filmsconnected only at the central core film, illustrating the refillabletandem tubes created by the B film air passage for area one air chambersand the A film air passageway for area two air chambers

FIG. 21 is a completed sealed perspective view of FIG. 20, illustratingthe relationship of area one and two air chambers and the central corefilm.

FIG. 22 is a perspective view of an inflated top to bottom and side toside two area redundant reusable high volume cushion with refillabletandem tubes, illustrating an open entry/exit portal tube.

FIG. 23 is a close-up view of an inflated top to bottom and side to sidetwo area redundant reusable high volume cushion, illustrating an openentry/exit portal tube.

FIG. 24 is a perspective view of an inflated top to bottom and side toside two area redundant reusable high volume cushion, illustrating theclosed position of the entry/exit portal tube in the tuck-away pocket.

FIG. 25 is a component view of the top to bottom and side to sidefour-area redundant reusable high volume cushion, illustratingrelationship between the A and B film entry/exit portal tube, first andsecond central core film and area conical air chamber layout and thecenter C film that creates the four areas.

DETAILED DESCRIPTION OF THE INVENTION

The invention is therefore directed to a redundant reusable high volumecushion with refillable tandem tubes wherein inflation and deflation ofeach area is independently controlled by and entry/exit portal comprisedof a entry/exit portal tube and portal tube tuck-away, and furtherwherein each said area is comprised of a plurality of, preferablycone-shaped, chambers configured and adapted to help absorb an impactthereupon and, upon such impact, to redistribute air within the cushionfrom a compressed chamber to a non-compressed chamber, for improving thereliability of the cushion.

Turning now to a description of the components illustrated in thedrawing figures, which is thereafter followed by a discussion of howthese various components work together in the invention,

FIG. 1 illustrates top plan view of a side by side two area cushionfirst conical air chamber of area one (1), area one passageway (2),connecting air chamber one (1) and conical air chamber two (3) In areaone. First conical air chamber of area two (7), area two passageway (6),connecting air chamber one (7) and conical air chamber two (5) In areatwo. Entry/exit Portal Tube (12), controlling airflow into and out ofthe cushion. Area one entry/exit passageway (14), allowing air movementthrough area one portal (9). Area two entry/exit passageway (13),allowing air movement through area two portal (10). Tuck-away (8),creating a pocket to secure the closed entry/exit Portal Tube (12).Extra wide heat welded outer seam (4), seam reduction at entry/exitportal tube (11).

FIG. 2 illustrates perspective view of a side by side two area cushionfirst conical air chamber of area one (1), area one passageway FIG. 1(2), connecting air chamber one (1) and conical air chamber two (3) Inarea one. Entry/exit refillable tandem Portal Tube (12), controlling airflow into and out of the cushion. Area one entry/exit passageway (14),allowing air movement through area one portal FIG. 1(9). Area twoentry/exit passageway (13), allowing air movement through area twoportal FIG. 1(10).

FIG. 3 illustrates component view of a side by side two area cushion,with A and B film layouts first conical air chamber of area one layouton film A (1 a), area one passageway FIG. 1 (2), connecting air chamberone layout in film A (1 a) and conical air chamber two layout on film A(3 a) In area one. First conical air chamber layout on film A of areatwo (7 a), area two passageway layout on film A (6 a), connecting airchamber one layout on film A (7 a) and conical air chamber two layout onfilm A (5 a) In area two. Entry/exit refillable tandem Portal Tubelayout on film A (12 a), controlling air flow into and out of thecushion. Area one entry/exit passageway layout on film A (14 a),allowing air movement through area one portal FIG. 1 (9). Area twoentry/exit passageway layout on film A (13 a), allowing air movementthrough area two portal FIG. 1 (10). Tuck-away (8), creating a pocket tosecure the closed entry/exit refillable tandem Portal Tube FIG. 1 (12)first conical air chamber of area one layout on film B (1 b), area onepassageway FIG. 1 (2), connecting air chamber one layout in film B (1 b)and conical air chamber two layout on film B (3 b) In area one. Firstconical air chamber layout on film B of area two (7 b), area twopassageway layout on film B (6 b), connecting air chamber one layout onfilm B (7 b) and conical air chamber two layout on film B (5 b) In areatwo.

FIG. 4 illustrates perspective view of inflated side by side two areacushion first conical air chamber of area one (1), area one passageway(2), connecting air chamber one (1) and conical air chamber two (3) Inarea one. First conical air chamber of area two (7), area two passageway(6), connecting air chamber one (7) and conical air chamber two (5) Inarea two. Entry/exit Portal Tube FIG. 1(12), controlling airflow intoand out of the cushion. Area one entry/exit passageway (14), allowingair movement through area one portal FIG. 1(9). Area two entry/exitpassageway (13), allowing air movement through area two portal FIG. 1(10). Tuck-away (8), creating a pocket to secure the closed entry/exitPortal Tube (12).

FIG. 5 illustrates perspective view of inflated side by side two areacushion with the refillable tandem entry/exit portal tube in the openposition

FIG. 6 is a perspective close-up view of an inflated side by side twoarea redundant reusable high volume cushion, illustrating the inflatedentry/exit portal tube, first conical air chamber of area one (1), Firstconical air chamber of area two (7), Tuck-away (8), Entry/exit PortalTube (12), controlling airflow into and out of the cushion. Area oneentry/exit passageway (14), allowing air movement through area oneportal FIG. 1(9). Area two entry/exit passageway (13), allowing airmovement through area two portal FIG. 1 (10).

FIG. 7 is a close-up front view of an inflated side by side two arearedundant reusable high volume cushion, illustrating the inflatedentry/exit portal tube (12), first conical air chamber of area one (1),First conical air chamber of area two (7), Tuck-away (8)

FIG. 8 is a close-up front view of the side by side two-area redundantreusable high volume cushion, illustrating the inflated entry/exitportal tube (12), with the first closing fold first conical air chamberof area one (1), First conical air chamber of area two (7), Tuck-away(8)

FIG. 9 is a close-up front view of the side by side two-area redundantreusable high volume cushion, illustrating the inflated entry/exitportal tube (12), with the second closing fold first conical air chamberof area one (1), First conical air chamber of area two (7), Tuck-away(8)

FIG. 10 is a close-up front view of side by side two-area redundantreusable high volume cushion, illustrating the inflated entry/exitportal tube (12), in the tuck-away position first conical air chamber ofarea one (1), First conical air chamber of area two (7), Tuck-away (8)

FIG. 11 is a perspective view of an inflated side by side two arearedundant reusable high volume cushion, illustrating the closedtuck-away position of the entry/exit portal tube (12), first conical airchamber of area one (1), area one passageway FIG. 1 (2), connecting airchamber one (1) and conical air chamber two (3) In area one. Firstconical air chamber of area two (7), area two passageway FIG. 1(6),connecting air chamber one (7) and conical air chamber two (5) In areatwo. Entry/exit Portal Tube (12), controlling airflow into and out ofthe cushion. Area one entry/exit passageway FIG. 1 (14), allowing airmovement through area one portal FIG. 1(9). Area two entry/exitpassageway FIG. 1(13), allowing air movement through area two portalFIG. 1 (10). Tuck-away (8), creating a pocket to secure the closedentry/exit Portal Tube (12).

FIG. 12 illustrates component view of a side by side four area cushion,with A and B film layouts and the third film C (15), that divides thecushion in half creating the four areas, the first area is divided intoareas one and three, and the second area is divided into areas two andfour. First conical air chamber of area one layout on film A (1 a), areaone passageway FIG. 1 (2), connecting air chamber one layout in film A(1 a) and conical air chamber two layout on film A (3 a) In area one,film C (15) divide this area in half allowing film A and film B tocreate areas one and three. First conical air chamber layout on film Aof area two (7 a), area two passageway layout on film A (6 a),connecting air chamber one layout on film A (7 a) and conical airchamber two layout on film A (5 a) In area two, film C (15) divide thisarea in half allowing film A and film B to create areas two and four.Entry/exit Portal Tube layout on film A (12 a), controlling air flowinto and out of the cushion. Area one entry/exit passageway layout onfilm A (14 a), allowing air movement through area one portal FIG. 1 (9).Area two entry/exit passageway layout on film A (13 a), allowing airmovement through area two portal FIG. 1 (10), film C (15) divides theportal tube into four entry/exit tubes supporting four areas. Tuck-away(8), creating a pocket to secure the closed entry/exit Portal Tube FIG.1 (12) first conical air chamber of area one layout on film B (1 b),area one passageway FIG. 1 (2), connecting air chamber one layout infilm B (1 b) and conical air chamber two layout on film B (3 b) In areaone, film C (15) divide this area in half allowing film A and film B tocreate areas one and three. First conical air chamber layout on film Bof area two (7 b), area two passageway layout on film B (6 b),connecting air chamber one layout on film B (7 b) and conical airchamber two layout on film B (5 b) In area two, film C (15) divide thisarea in half allowing film A and film B to create areas two and four.

FIG. 13 is a top plan view of the side by side two-area or four-arearedundant reusable high volume cushion, illustrating layout orientationof two separate cushions in a production layout Cushions are arranged tocreate a production pair improving raw material film usage.

FIG. 14 is a top plan view of the side by side two-area or four-arearedundant reusable high volume cushion, illustrating layout orientationof two separate cushions and additional similar arranged cushions in aproduction layout to accommodate rolled or sheet film raw material.Production pairs can be rolled or stamped out of film rolls or filmsheets for efficient production.

FIG. 15 illustrates top plan view of a top to bottom and side to sidetwo area cushion first conical air chamber of area one (1), area onepassageway (2), connecting air chamber one (1) and conical air chambertwo (3) In area one. First conical air chamber of area two (7), area twopassageway (6), connecting air chamber one (7) and conical air chambertwo (5) In area two. Entry/exit Portal Tube (12), controlling airflowinto and out of the cushion. Area one entry/exit passageway (14),allowing air movement through area one portal (9) . Area two entry/exitpassageway (13), allowing air movement through area two portal (10).Tuck-away (8), creating a pocket to secure the closed entry/exit PortalTube (12). Extra wide heat welded outer seam (4), seam reduction atentry/exit portal tube (11). Central core film (16), that creates thepassageway (2), for area one air chambers and passageway (6), for areatwo air chambers.

FIG. 16 illustrates perspective view of a top to bottom and side to sidetwo area cushion first conical air chamber of area one (1), area onepassageway FIG. 15 (2), connecting air chamber one (1) and conical airchamber two (3) In area one. Entry/exit Portal Tube (12), controllingair flow into and out of the cushion. Area one entry/exit passagewayFIG. 15 (14), allowing air movement through area one portal FIG. 15 (9).Area two entry/exit passageway FIG. 15 (13), allowing air movementthrough area two portal FIG. 15 (10). Tuck-away (8), creating a pocketto secure the closed entry/exit Portal Tube (12).

FIG. 17 is a component view of the top to bottom and side to sidetwo-area redundant reusable high volume cushion, illustratingrelationship between the A film, B film and central core film (16),first conical air chamber of area one layout on film A (1 a), area onepassageway FIG. 15 (2), connecting air chamber one layout in film A (1a) and conical air chamber two layout on film A (3 a) In area one. Firstconical air chamber layout on film A of area two (7 a), area twopassageway layout on film A (6 a), connecting air chamber one layout onfilm A (7 a) and conical air chamber two layout on film A (5 a) In areatwo. Entry/exit Portal Tube layout on film A (12 a), controlling airflow into and out of the cushion. Area one entry/exit passageway layouton film A (14 a), allowing air movement through area one portal FIG. 15(9). Area two entry/exit passageway layout on film A (13 a), allowingair movement through area two portal FIG. 1 (10). Tuck-away (8),creating a pocket to secure the closed entry/exit Portal Tube FIG. 15(12), first conical air chamber of area one layout on film B (1 b), areaone passageway FIG. 15 (2), connecting air chamber one layout in film B(1 b) and conical air chamber two layout on film B (3 b) In area one.First conical air chamber layout on film B of area two (7 b), area twopassageway layout on film B (6 b), connecting air chamber one layout onfilm B (7 b) and conical air chamber two layout on film B (5 b) In areatwo. Central core film (16), that creates the passageway FIG. 15 (2),for area one air chambers and passageway FIG. 15 (6), for area two airchambers.

FIG. 18 is a top perspective view of the top to bottom and side to sidetwo area redundant reusable high volume cushion central core film FIG.15 (16), illustrating the heat-weld seams (17),in the A film that createair passageway (6) for the area two air chambers FIG. 15 (7) (5).Reference FIG. 17 (1 a) and (5A) for film positions.

FIG. 19 is a through perspective view of the top to bottom and side toside two area redundant reusable high volume cushion central core filmFIG. 15 (16), illustrating the heat-weld seams (19), in the B film thatcreate air passageway (2), for the area one air chambers FIG. 15 (1)(3), and their relationship to area two air passageway (6). ReferenceFIG. 17 (1 a),(5 a),(1 b),(5 b) for film positions.

FIG. 20 is a through perspective view of the top to bottom and side toside two area redundant reusable high volume cushion with A and B filmsconnected only at the central core film FIG. 17 (16), illustrating the Bfilm air passageway (2), created by heat welds FIG. 19 (19), for areaone air chambers FIG. 15 (1) (3), and the A film air passageway (6),created by heat weld FIG. 18 (17), for area two air chambers FIG. 15 (7)(5). Reference FIG. 17 (1 a),(5 a),(1 b),(5 b) for film positions.

FIG. 21 is a completed sealed perspective view of FIG. 20, illustratingthe relationship of area one and two air chambers and the central corefilm (16), first conical air chamber of area one (1), area onepassageway (2), connecting air chamber one (1) and conical air chambertwo (3) In area one. First conical air chamber of area two (7), area twopassageway (6), connecting air chamber one (7) and conical air chambertwo (5) In area two. Entry/exit Portal Tube FIG. 15 (12), controllingairflow into and out of the cushion. Central core film (16) that createsthe passageway (2), for area one air chambers and passageway (6), forarea two air chambers.

FIG. 22 is a perspective view of an inflated top to bottom and side toside two area redundant reusable high volume cushion, illustrating anopen entry/exit portal tube (12), first conical air chamber of area one(1), area one passageway FIG. 15 (2), connecting air chamber one (1) andconical air chamber two (3) In area one. First conical air chamber ofarea two (7), area two passageway FIG. 15 (6), connecting air chamberone (7) and conical air chamber two (5) In area two. Entry/exit PortalTube (12), controlling airflow into and out of the cushion. Area oneentry/exit passageway FIG. 15(14), allowing air movement through areaone portal FIG. 15 (9). Area two entry/exit passageway (13), allowingair movement through area two portal FIG. 15 (10). Tuck-away (8),creating a pocket to secure the closed entry/exit Portal Tube (12).

FIG. 23 is a close-up view of an inflated top to bottom and side to sidetwo area redundant reusable high volume cushion FIG. 22, illustrating anopen entry/exit portal tube (12).

FIG. 24 is a perspective view of an inflated top to bottom and side toside two area redundant reusable high volume cushion, illustrating theclosed position of the entry/exit portal tube (12), in the tuck-awaypocket (8), first conical air chamber of area one (1), area onepassageway FIG. 15 (2), connecting air chamber one (1) and conical airchamber two (3) In area one. First conical air chamber of area two (7),area two passageway FIG. 15 (6), connecting air chamber one (7) andconical air chamber two (5) In area two. Entry/exit Portal Tube (12),controlling airflow into and out of the cushion in the closed tuck-awayposition.

FIG. 25 is a component view of the top to bottom and side to sidefour-area redundant reusable high volume cushion, illustratingrelationship between the A and B film entry/exit portal tube (12), firstand second central core film (16), (21), and the center C film (22) thatcreates the four areas, separating area one into areas one and three,and separating area two into area two and four. First conical airchamber of area one layout on film A (1 a), area one passageway FIG. 15(2), connecting air chamber one layout in film A (1 a) and conical airchamber two layout on film A (3 a) In area one, film C divide this areain half allowing film A and film B to create areas one and three. Firstconical air chamber layout on film A of area two (7 a), area twopassageway layout on film A (6 a), connecting air chamber one layout onfilm A (7 a) and conical air chamber two layout on film A (5 a) In areatwo, film C divide this area in half allowing film A and film B tocreate areas two and four. Entry/exit Portal Tube layout on film A (12a), controlling air flow into and out of the cushion. Area oneentry/exit passageway layout on film A (14 a), allowing air movementthrough area one portal FIG. 15 (9). Area two entry/exit passagewaylayout on film A (13 a), allowing air movement through area two portalFIG. 1 (10). Tuck-away (8), creating a pocket to secure the closedentry/exit Portal Tube FIG. 15 (12), first conical air chamber of areaone layout on film B (1 b), area one passageway FIG. 15 (2), connectingair chamber one layout in film B (1 b) and conical air chamber twolayout on film B (3 b) In area one, film C divide this area in halfallowing film A and film B to create areas one and three. First conicalair chamber layout on film B of area two (7 b), area two passagewaylayout on film B (6 b), connecting air chamber one layout on film B (7b) and conical air chamber two layout on film B (5 b) In area two, filmC divide this area in half allowing film A and film B to create areastwo and four. Central core film (16), that creates the passageway FIG.15 (2), for area one air chambers and passageway FIG. 15 (6), for areatwo air chambers.

As shown in the accompanying drawing figures, the present systemincludes everything needed to provide a redundant reusable high volumesystem that can be inflated, deflated, and reused. The redundantreusable high volume cushion of this invention is thus designed to holdan item or inner package secure in a exterior shipping carton. Theredundant reusable high volume cushion may be configured, in a firstembodiment in a two area format (Side by Side areas FIG. 1, and Top toBottom Side to Side FIG. 15) wherein the two areas are created bybonding two film sheets together (Side by Side FIG. 3 and Top to BottomSide to Side FIG. 17) to provide air chambers for each area, and, in asecond embodiment, with a four area design (Side by Side areas FIG. 12and Top to Bottom Side to Side areas FIG. 25) created by heat weldingthree full film sheets, ((FIG. 12, FIG. 25) with the central core film(16)(21) FIG. 25, for the top to bottom side to side design (FIG. 15))together, with the central film sheet (see (15) in FIG. 12, and, (22) inFIG. 25) creating the air chambers for each area.

Additional security is provided by the use of a geometric, heat weldeddesign providing controlled areas to receive impact compressed air (seeFIG. 1 (1) (3) (7) (5), and FIG. 15 (1)(3) (7) (5) within the cushion.Extra wide exterior seam (FIG. 1 (4)) and narrower interior field seamsadd cushion integrity by allowing severe impact to open an interior seammoving air into adjacent areas, instead of an exterior seam rupture,allowing air to escape the cushion enclosure.

Additional cushion volume is provided by the layout of each geometricformat, shape are placed side by side, maximizing the inflated cushionsurface, and providing greater depth in cushion height.

Cushion areas each comprise redundant interconnected air chambers toprovide each cushion with the maximum ability to absorb impact bydistributing air to chambers not compressed by impact. The cushions ofthe invention may be formed of any number and type of film substratesthat can be welded together by, e.g., applying heat, or by an electricalor chemical bonding process. Materials useful in the formation of thefilms used in forming the invention are well known among those ofordinary skill in this field and the particular choice of material isnot critical to the invention. Moreover, varying the film thicknessprovides for varying levels of cushion strength and security, and can bedictated as the product to be shipped or budget require. Virtually anyfilm that can hold air can be securely welded together can be used tocreate a area redundant reusable high volume cushion in accordance withthe invention.

The air in each area of a cushion is retained by a entry/exit portaltube (see FIG. 1 (12), FIG. 15 (12)), and tuck-away film, (see FIG. 1(8), FIG. 15 (8)), once the cushion is filled with air the (see FIG. 5and FIG. 22) the entry/exit portal tube is folded twice over itself,(see FIG. 7, FIG. 8, FIG. 9), and then tucked under the tuck-away film(see FIG. 11 and FIG. 24) The tuck-away film is heat sealed to the frontand left exterior seam, (see FIG. 1 (8), and FIG. 15 (8)). Creating apocket to receive the folded entry/exit portal tube (see FIG. 10). Asnoted the folds in the entry/exit portal tube (see FIG. 8, FIG. 9 andFIG. 10), provide a series of locking point, adding to cushion security.Deflate each cushion by moving the entry/exit portal tube from thetuck-away pocket and opening the folds, deflated cushions can be reusedby blowing air into the entry/exit portal tube, (FIG. 1 (12), FIG. 15(12)),and securing the folded tube in the tuck-away pocket, (FIG. 10),as described above. Interior air pressure forced against the portal area(FIG. 1 (9), (10) and FIG.>15 (9),(10)), will press the tube tighterinto the tuck-away pocket (FIG. 11(8) and FIG. 24(8)), adding andadditional level of security.

Type of two area cushions, are distinguished by the placement of anareas air chambers. In the side by side format, one area controls thefront and left side of the cushion while the opposite area controls theleft side and back of the cushion. In the top to bottom and side toside, one area controls the front and back of the cushion while theother area controls the left and right side. The side by side is builtby welding and A film and B film together with a tuck-away film weldedto the left and front exterior seam. The top to bottom side to side isbuilt welding the A film and B film to a central core film, (to createthe passageways for each area), then to each other, with a tuck-awayfilm welded to the left and front exterior seam.

The four-area redundant reusable high volume cushion (FIG. 12, FIG. 25)of the invention has all the features of the two-area system, (includingan additional, i.e., second central core film, (FIG. 25(21) for the topto bottom side to side cushion), with the same features of air entry,locking and release in the same manner described above for the two areacushion. Additional security is offered by the four-area cushion in thatthere is a central film layer (see(15) FIG. 12 and (22) FIG. 25), ineach four-area cushion that divides the inflated sections into fourcomplete areas. The interior film provides an additional area forabsorbing impact. That is, when one of the exterior film areas (see FIG.12 and FIG. 25), is subjected to impact, the resulting force can beabsorbed by this soft flexible middle film layer (shown as (15) in FIG.12 and (22) in FIG, 25).

This multi-area feature adds a level of puncture resistance to thecushion surface. That is, the use of four areas allows the cushion tomaintain a greater level of integrity if a area is punctured.

It is to be understood that the present invention is not limited inscope by the exemplified embodiments which are intended as illustrationsof single aspects of the invention, and the embodiments and methodswhich are functionally equivalent are within the scope of the invention.Indeed, various modifications of the invention in addition to thosedescribed herein will become apparent to those skilled in the art fromthe foregoing description.

1. A redundant reusable high volume cushion with refillable tandem tubesfor cushioning articles during shipping and handling, said redundantreusable high volume cushion made of a first and second outer filmlayers, said first and second film layers being secured together alongan outer perimeter to define the refillable tandem tubes permittingcushion reusability.
 2. A redundant reusable high volume cushion withrefillable tandem tubes comprised of a plurality of inflatable conicalshaped chambers configured to redistribute an inflation gas containedtherein from one or more conical shaped chambers compressed by andexternal impact to at least one contiguous conical shaped chamber whichis not impacted.
 3. The system of claim 2, wherein said conical shapedchambers maximize cushion height for impact protection, said cushionheight respective of available chamber height, determined by base widthof conical chambers provided.
 4. A Redundant Reusable High VolumeCushion with refillable tandem tubes supporting four cushion areas, tocushion articles during shipping and handling, redundant reusable highvolume cushion use the inner volume to form four separate cushion areasconical shaped areas providing a high volume profile.